Integrated Bogie Assembly Line automation - Nagraj V Pandit The - - PowerPoint PPT Presentation

Integrated Bogie Assembly Line automation

• Nagraj V Pandit

• Touches the lives of over 1.1 billion consumers everyday, across the globe
• Generates revenues of USD 5 billion, annually
• Constantly builds and leverages the brand Godrej that is synonymous with:
• Trust, Reliability, Integrity and Innovation
• Employs over 20,000 people globally - The Godrej ‘Parivaar’
• Maintains a campus of about 3000 acres of land in Mumbai, India

The Godrej Group today

Godrej at Vikhroli, Mumbai

Defense & Aerospace Home and Personal care Agriculture Real Estate Industrial Chemicals Home Appliances Furniture for Homes and Offices Warehousing Solutions Software Foods & Grocery Precision Engineering Security Solution Process Equipment Tooling

…and over 60 lines of business

Material Handling

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Godrej & Boyce Mfg Co. Ltd

Locks Furniture & Interior Security Equipments Prima communication Solutions Appliances Storage Solutions

Tooling

Material Handling Equip. Process Equipment Precision Engg. Systems Precision Components & Systems Construction Tech Services Property development Enviro-tech Services Electrical & Electronics

Consumer Products Services Industrial Products Business Verticals

Integrated Bogie Assembly Line automation

The journey started……

Area of concerns (MCF) Offered solution by Godrej

Lower out turn of bogies per shift. Increase in productivity by 100% Conventional way of assembly Assembly line concept as used in Auto industry. Manual data recording, storing & retrieval IoT enabled line. Online Data acquisition & storage on server Automatic report generation, easy access & retrieval. Difficulty in component tracking Easy to track the component due to QR codes. Operator fatigue Effortless handling and improved ergonomics Material flow from different locations Improved material flow for assembly line 5’s on shop floor

• Collaborative approach by Railways
• Technical inputs from MCF officials in

concept development

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Salient Features

Before Transfer of component through Trolleys After Streamlined assembly flow Bogie Rotation manipulator

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Salient Features

High precision transducerized Power tools improve operator efficiency & Quality Daily production dashboard Component tracking and automatic report generation Before After

5’S by customised Pallets & Tables

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Industry 4.0

• Wireless data connectivity
• Smart IoT enabled tools &

sensors

• Establishment of digital

record

• Data storage in cloud
• Easy root cause analysis

and its mitigation plan.

• Step towards smart

manufacturing

1970

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Torque value & Component ID Torqueing program selection Component, Vendor, Torque, Production date

Station 1 Station 2 Finished

4 key components in Industry 4.0

Sense ID and parameters Acquire master data / transactional data from ERPs Visualize data in Dashboards / Control towers Interpret via Analytics and Models to Aid Decision Making

IoT / Industry 4.0 Implementation at MCF Raebareli

Industry 4.0

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Industry 4.0 – IoT Journey

Objectives

• Ensure right amount of

torque delivered for every possible bogie component

• Bring maximum possible

traceability

• Generate Report with

maximum automation

Approach

• Use Track and Trace platform

(dataSAVI) to deliver solution

• Consider Robust handheld

devices like industrial scanners, torque guns

• Use QR code instead of

Barcode for better scanning

• Use Server based Data

Logging instead of classical data loggers

• Seamless integration

between devices and cloud

Solution

• QR code based system to

build traceability.

• Close loop system to deliver

exact amount of torque

• Live Production dashboards
• Cloud enabled solution

(Monitor production from anywhere in the world)

• Ability to further Add

Analytics Layer over time as the System matures

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Benefits

• System generated SIP report for each bogie

with torque data

• System generated Traceability report
• Better Uptime monitoring
• Plan vs Actual monitoring

Opportunities / Future Enhancements within MCF

• Consider Other Processes for similar Track

and Trace

• Integration with existing ERP
• Leverage actuals for PPC
• Statistical Process Control
• Process capability index
• Warranty Management
• Better Traceability leading to better

Maintenance Management

Industry 4.0 – IoT Journey

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Operator Supervisor

Component QR coding – Schematic Process

QR code Printing QR code Sticking on components Component – Bogie Mapping Component Torqueing Scan Component Report QR code Generator

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Production Dashboard – Real Time Updated System Available on Cloud and Mobile App

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SIP Report – Automated Report from System

Assembly Line Layout – Plan View

Flow ofAssembly

Station 4

• Cross section Handling & fitment
• Lateral bump stop Fitment.
• Centering disc (Upper & Lower Handling)
• Bolster sub-assembly
• Fork arm & longitudinal fitment
• Lifting of Inverted Bogie Bolster
• Placement on secondary suspension
• Rod link & fork fitment by 50T press
• Center pivot & traction center fitment
• Lateral Dampener fitment.
• Secondary Dampener Fitment

Station 0

• Placement of Inverted

Bogie frame over Trolley

• Pneumatic piping

Station 1 Tightening & Handling of

• Traction Center Assembly
• Anti Roll bar Assembly
• Brake Caliper Assembly

Station 2

• Primary Suspension Handling
• Upper Control Arm Assembly

Station 3

• Handling of wheel axle
• Lower Control Arm Assembly
• Phonic wheel fitment
• Control Arm Side Cover Fitment
• Fitment of earthing device
• Lifting of Bogie Frame
• Removal of Trolley
• Bogie Frame Inversion

Integrated Bogie Assembly Line

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Thank you